Intake Manifold

Intake Manifold

If the fuel rail is removed or replaced, the intake manifold runner position sensor (G336) must be adapted to the Engine Control Module (ECM) (J623). Use a vehicle diagnosis tester.

Special tools, testers and auxiliary items required

• Assembly Tool (T10118)

• Hose Clip Pliers (V.A.G 1921)

• Socket Torx(R) T30 (T10347)

• Hazet Oil Filter Wrench (2171-1) or an Oil Filter Wrench (3417)

Removing

• It is necessary to remove the intake manifold and fuel rail in order to be able to get to the fuel injectors.

• The combustion chamber seal (Teflon(R)) and the O-ring must always be replaced.

• Intake manifold assembly overview, refer to => [ Intake Manifold Overview ] Intake Manifold Overview

• Fuel rail assembly overview, refer to => [ Fuel Rail Overview ] Fuel Rail Overview

Fuel system is under pressure! Fuel pressure must be reduced to a residual pressure before opening high pressure area of injection system. Refer to => [ Releasing Pressure in High Pressure Area ] Description and Operation.

- Disconnect the battery Ground (GND) cable.

- Remove the engine cover.

- Disconnect the vacuum line - arrow - to the Evaporative Emission (EVAP) canister.






- Disconnect the following electrical connectors.

1 EVAP canister purge regulator valve 1 (N80)
2 From the Knock Sensor (KS) 1 (G61)
3 From the Intake Manifold Runner Control (IMRC) valve (N316) , Fuel Pressure Sensor (G247) and the Camshaft Position (CMP) sensor (G40)
4 From the fuel injectors
5 Throttle valve control module (J338)
6 Intake Air Temperature (IAT) sensor (G42)

Disconnect the connector - 1 - from the CMP sensor.






- Open the air guide hose clamp - arrow - and remove the hose from the throttle valve control module.






- Disconnect the vacuum line - 1 - at the separating point - 2 -.






- Remove the crankcase ventilation hose - 3 -.

- Open the spring clamp - upper arrow - and remove the fuel supply line from the high pressure pump.






- Open the high pressure fuel line union nut - lower arrow - on the high pressure pump.

• The fuel system must have no pressure.

• Use a clean cloth to absorb exiting fuel.

• Seal the open connections with clean caps and make sure no dirt has entered the fuel system.

- Remove the vacuum line - arrow - from the IMRC valve.






- Remove the coolant line bolt - arrow - from the intake manifold.






- Disconnect the connector from the fuel pressure sensor - 1 -.






- Loosen the mounting nut - 1 - slightly and remove the bolt - 2 - completely.






- Remove the oil filter with a (2171-1) or an (3417).






- Remove the intake manifold bolts using (T10347).

• The throttle valve control module must be removed in order to remove any bolts that are not accessible and not using the (T10347).

- Carefully pull the intake manifold with fuel rail away from the cylinder head slightly.

- Disconnect the connector - 1 - from the intake manifold runner position sensor and remove the intake manifold.






• The fuel injectors could remain stuck in the fuel rail.

• Seal the intake channels with a clean cloth.

- Separate the intake manifold from the fuel rail. Refer to => [ Fuel Rail ] Fuel Rail.

Installing

• Make sure the fuel injectors are installed correctly.

- Mount the intake manifold onto the cylinder head on the stud bolts (lower left and right).

- Install in reverse order of removal.

• Tightening specifications: Intake manifold assembly overview, refer to => [ Intake Manifold Overview ] Intake Manifold Overview

• Tightening specifications: Fuel rail assembly overview, refer to => [ Fuel Rail Overview ] Fuel Rail Overview